CA1157965A - Method for developing a pattern on a ceramic substrate - Google Patents
Method for developing a pattern on a ceramic substrateInfo
- Publication number
- CA1157965A CA1157965A CA000379582A CA379582A CA1157965A CA 1157965 A CA1157965 A CA 1157965A CA 000379582 A CA000379582 A CA 000379582A CA 379582 A CA379582 A CA 379582A CA 1157965 A CA1157965 A CA 1157965A
- Authority
- CA
- Canada
- Prior art keywords
- oxygen
- oxygen barrier
- ceramic substrate
- heat
- barrier material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
- C03C17/06—Surface treatment of glass, not in the form of fibres or filaments, by coating with metals
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/51—Metallising, e.g. infiltration of sintered ceramic preforms with molten metal
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/85—Coating or impregnation with inorganic materials
- C04B41/88—Metals
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/84—Heating arrangements specially adapted for transparent or reflecting areas, e.g. for demisting or de-icing windows, mirrors or vehicle windshields
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C2217/00—Coatings on glass
- C03C2217/20—Materials for coating a single layer on glass
- C03C2217/25—Metals
- C03C2217/251—Al, Cu, Mg or noble metals
- C03C2217/252—Al
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C2217/00—Coatings on glass
- C03C2217/20—Materials for coating a single layer on glass
- C03C2217/25—Metals
- C03C2217/251—Al, Cu, Mg or noble metals
- C03C2217/253—Cu
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C2217/00—Coatings on glass
- C03C2217/20—Materials for coating a single layer on glass
- C03C2217/29—Mixtures
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C2218/00—Methods for coating glass
- C03C2218/10—Deposition methods
- C03C2218/17—Deposition methods from a solid phase
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/016—Heaters using particular connecting means
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- General Chemical & Material Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Life Sciences & Earth Sciences (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Surface Heating Bodies (AREA)
- Surface Treatment Of Glass (AREA)
- Resistance Heating (AREA)
Abstract
ABSTRACT
A method for developing a pattern of electrically conductive material on a ceramic substrate is disclosed.
The method includes the steps of depositing on the ceramic substrate in a desired pattern a thin layer of a heat fusable material which contains a granular current conducting base metal. An encasing layer is deposited over the pattern formed of the heat fusable material. The encasing layer is formed from an oxygen barrier material containing an oxygen getting material. This encasing layer is non-heat fusable and nonreactive with the heat fusable material. All of this structure is heated in an oxygen containing ambient to a temperature sufficient to permit the heat fusable material to fuse to the ceramic substrate.
The oxygen barrier material protects the granular, current conducting base metal of the fusable material from oxidation by physically blocking out oxygen and by chemically providing an oxygen getting material which will react with any oxygen which does manage to penetrate into the oxygen barrier material. The ceramic substrate, fused heat fusable material, and remaining oxygen barrier material thereon are cooled back to room temperature and any remaining oxygen barrier material is removed from the ceramic substrate.
A method for developing a pattern of electrically conductive material on a ceramic substrate is disclosed.
The method includes the steps of depositing on the ceramic substrate in a desired pattern a thin layer of a heat fusable material which contains a granular current conducting base metal. An encasing layer is deposited over the pattern formed of the heat fusable material. The encasing layer is formed from an oxygen barrier material containing an oxygen getting material. This encasing layer is non-heat fusable and nonreactive with the heat fusable material. All of this structure is heated in an oxygen containing ambient to a temperature sufficient to permit the heat fusable material to fuse to the ceramic substrate.
The oxygen barrier material protects the granular, current conducting base metal of the fusable material from oxidation by physically blocking out oxygen and by chemically providing an oxygen getting material which will react with any oxygen which does manage to penetrate into the oxygen barrier material. The ceramic substrate, fused heat fusable material, and remaining oxygen barrier material thereon are cooled back to room temperature and any remaining oxygen barrier material is removed from the ceramic substrate.
Description
~ 1~79~
METHOD FOR DEVELOPING A PATTERN ON A
CERAMIC SUBSTRATE
_ The present invention relates to the formation of a pattern on a ceramic substrate.
We are unaware of any prior art which is relevant to the method of developing an electrically conductive pattern on a ceramic substrate which is to be disclosed herein.
Howe~er, Ford Motor Company did, in a companion case, conduct a novelty study on a similar subject matter in the U.S. Patent Office. The novelty study reported several patents, all of which appear to us to be irrelevant with respect to the subject matter disclosed and claimed in this application. A brief review of these patents will be set forth below.
A number of patents cited in the novelty study are patents which deal with the coating of a metal wire with a protective layer. The protective layer may be a glass layer, and in some applications, there are a number of layers of protectïve ma~erial laid one over the other. The U.S. patents in this $xw~ mcludethe following: 3,106,490;
3,109,053; 3,294,731; 3,325,590; 3,35~,009 and 3,451,847.
None of these patents are directed to a method of developing an electrically conductive pattern on a ceramic substrate, as is disclosed and specifically claimed in this application.
The other two patents cited in the novelty study were U.S. patents 3,721,594 and 3,928,748. ~oth of these patents deal with window structures which have electrically conductive patterns thereon. In the 3,721,594 U.S. Patent, a method is disclosed for electroless plating of a grid pattern on a window. ~owever, prior to the electroless plating, the glass window has a finely divided ceramic frit placed thereon and the frit and window are passed through a glass tempering operation. U.S. 3,928,748 patent shows a heater grid structure for a window which is also made in i 157'~
a manner in which it can also serve as a radio ~ltenna.
Neither of these patents disclose or suggest the method which we are going to disclose in this speci~ication.
This invention is directed to a method for developing a pattern on a ceramic substrate and, mare particularly, to a method for developing an electrically conductive pattern on a ceramlc substrate, such as a glass window, which is subsequently used in a motor vehicle as a heated ~acklite.
In accordance wlth the prese~t invention, an electrically conductive pattern is developed on a ceramic substrate in the following manner. A thin Iayer of a heat fusable material which contains a current conducting base metal in granular form is deposited on the ceramic substrate in a desired pattern. An encasing layer of an oxygen barrier material containing an oxygen getting material is deposited over the pattern formed of heat fusable material on the ceramic substrate. The oxygen barrier material forming the encasing layer is a material which is non-heat fusabre and nonreactive with the heat fusable material forming the pattern. The ceramic substrate, the heat fusable material and the oxygen barrier material supported on the ceramlc substrate are heated in an oxygen containing ambient. The heating is to a temperature sufficient to permit the heat fusable material to fuse to the ceramic substrate. 2uring this fusing, the oxygen barrier material protects the granular, current conducting base metal of the fusable material in two manners. In a first manner, the oxygen barrier material physically blocks out the oxygen. In a second manner, the oxygen barrier material provides the getting material which chemically reacts with any oxygen which does manage to penetrate into the oxygen oarrier material, thereby keeping such oxygen away from the otherwise oxidizable base metal 35 contained in the heat fusable material. The ceramic substrate, along with the now fused 'neat fusable material, and any remaining oxygen ~arrier material supported on the~
ceramic substrate is cooled to room temperature. Any '~;^, 1 1S75'6~
remaining oxygen barcler material is then removed from the ceramic substrate, thereby 2roviding a ceramic substrate with an electrically conductive 2attern thereon formed of a base metal.
In accocdance with some of the detailed teachings of the method of thls invention, the base metal can be selected from the group consisting of aluminum and copper.
The ceramic substrate can be formed from ordinary soda lime silica glass and be, for example, in the shape of a backlite normally used in a motor vehlcle.
In accordance with still further detailed aspects of this invention, if the ceramic substrate is selected to be a soda lime silica glass, the cooling step is carried out at a rate suf~iciently fast to accomplish a tempering 15 of the glass.
The novel features that are considered ~character-istic of the invention are set forth with particularlity in the appended claims. The lnvention itself, however, both as to ~ts organization and its method of operation, together wit~ advantages thereof, will best be understood from the following description of specific embodiments when read in connec~tion with the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures, and in which:
Figure 1 is a plan view of a heated backlite usa'ble in automotive vehicles made in accordance with the method of this invention;
Figure 2 is an enlarged view of a heated backlite during an initial stage of the method of this invention:
Figure 3 is a cross section view taken along line III-III of Figure 2;
Figure 4 is a view similar to Figure 2, but showing the heated backlite in a latter stage of the method of this invention:
Figure 5 is a cross section view taken along line V-V of Figure 4; and Figure 6 is a cross-section view similar to Figure 5 but showing the heated backlite in the last stage of the method of this invention.
1 1~79~
The method about to be described is used to form electrically conductive patterns on window glass. A
ærincipal use for such a window glass may be as a heatable window structure for an automobile. In particular, the greatest utility for such window glasses are as heated backlites in automotive vehicles. When the backlite is fogged or iced over, electrical energy is flowed~through the electrically conductive pattern, causing the pattern and glass window associated therewith to be heated. This heating action removes the fog or ice that is on the window. In normal cases, the number of lines, thickness of individual lines and resistance of the pattern to the flow of electrical energy therethrough determine the amount of heat that is generated per unit of time by such a heated backlite.
In Figure 1, there is illustrated a backlite generally designated by the numeral 10. This backlite is in the form of a glass sheet 12 having a conductive electric pattern formed thereon generally designated by the :r .1 1 157~G~
numeral 14. Tne conductive pattern has oppositely placed bus bars 1~ and 13 interconnected by a plurality o~ grid lines 20-20. ~lectric terminals 22 and 24 are provided respectively on bus bars 16 and 18 to provide a means for connecting the conductive grid pattern 14 to an electrical supply system. When the electrical supply system is connected to the conductive pattern and is in operating condition, the grid lines and bus bars associated therewith carry electrical power, which in turn generates heat to melt any ice or to dispell any fog that may be on the glass sheet 12.
The method of this invention is a method for applying the conductive pattern 14 to the glass sheet 12.
The method of this invention will best be understood by reference to Figures 2 through 6. A first step in the method of this invention is illustrated in Figure 2. In this Figure, there is shown disposed on the window 12 in a desired pattern a thin layer of a heat fusable material which contains a current conducting base metal in granular form in order to define the conductive pattern 14, shown only in Figure 1. This heat fusable material is a material such as a mixture of granular copper or granular aluminum with a low melting glass frit, a preferred heat fusable materia] containing about 90% by weight of the base metal, and 10~ by weight of the glass frit. This type of heat fusable material may be applied in 2 uniform manner in the required thickness, the thickness being determined by the conductivity of the metal involved as well as other electrical factors known to a skilled artisan to generate so much heat per square unit of the backlite.
In a preferred embodiment of the method of this invention; the heat fusable material which contains a current conducting base metal in ~ranular form is applied to the glass sheet 12 in order to form the conductive 3~ pattern 14 thereon in a silk screen printing operation, which operation is well known in the art. The silk 1 1S7~
screen process provides a mask that outlines the configuration to be printed on the glass sheet. After the heat fusable material has been deposited, it may be cured at low temperatures in order to effect a temporary bonding of that heat f~sable material to the glass sheet. For example, the sheet, with the prlnting thereon, can be heated and forced air dried at 400F.
As is best illustrated in Figure ~, after the pattern of the heat fusable material which contains a current conducting base metal in granular form has been deposited on the glass sheet 12 in the conductive pattern 14, there is deposited thereover in an encasing manner an encasing layer 26 of an oxygen barrier material containing an oxygen getting material. The oxygen barrier material is also one which is non-heat fusable and nonreactive with the heat fusable material enclosed. For example, the oxygen barrier material may be a clay powder mixed with granular charcoal. The granular charcoal acts as the oxygen getting material of the oxygen barrier material.
By an oxygen barrier material it is meant a material which when placed over another material will act in a manner to bar entrance of oxygen to the enclosed material because of the manner in which the barrier material is packed over the encased material. By an oxygen getting material it is meant a material which is reactive with oxygen so that if the oxygen barrier material is penetrated by some oxygen from an oxygen ambient, the getter material will react with the oxygen and thereby protect the material lying therebelow which is enclosed.
If that material had not been protected, the base metal forming the conductlve pattern would be free to oxidize and have its electrical characteristics destroyed.
1 157~6~
In accordance with the teachings of this preferred embodiment, a dual purpose heating operation is now carried out on the glass sheet 12, the conductive pattern 14, and the oxygen barrier material 26 deposited over the conauctive pattern. The heating is to a temperature in a range of about 1100F to 1200F. Glass, when rapidly cooled from this temperature range, will be tempered. As an additional matter, when the glass sheet is 'neated to this temperature, the t'nin heat fusable material forming the conductive pattern fuses together to form an electric pattern adherent to the glass which is capable of conducting electricity therethrough for the purpose of defogging and deicing the sheet. During the heating of the glass to this elevated temperature, and while at the elevated temperature, the glass is maintained in an oxygen amb ent such as air. The reason that it is maintained ln such an ambient is that there would be tremendous costs involved if one attempted to heat such a glass sheet in an environment such as all nitrogen gas and also use all nitrogen gas in a tempering operation.
While the glass article is heated to the elevated temperature and maintained in an oxygen ambient, the oxygen barrier material 26 provides a protective coating over the conductive pattern 14 which prevents the oxidation thereof.
~The oxidation is prohibited in two manners. In a first manner, the oxygen barrier material acts as a physical barrier to exclude oxygen from the conductive pattern. In a second manner, the oxygen barrier material provides oxygen getting capabilities which, as previously explained, means that the oxygen barrier material provides a material which will reacts with any oxygen that does in fact permeate thro~gh the barrier material rather than permitting the base metal forming the conductive pattern to react with such oxygen. The oxygen barrier material, however, is one which is non-heat fusable and nonreactive with the conductive pattern it is protecting.
I lS ~g( As is well known in the art, in order to temper a glass sheet it is rapidly cooled from an elevated temperature to room temperature by the impingement of cooling air thereon. If the intended glass sheet is a product which is to be used in a motor vehicle, it will be necessary to temper the glass sheet in order to comply with the requirements of automotive glazing. Thus, if the glass sheet is to be used as a backlite in a motor vehicle, the glass sheet will be quenched rapidly from its elevated temperature to room temperature to temper the same.
During the cooling of the glass, some or all of the oxygen barrier material 26 may be blown off or blown away to expose therebelow the conductive pattern 14.
~fter the glass sheet has reached room temperature, any oxygen barrier material remaining over the conductive pattern may be washed or wiped away in order to expose the conductive pattern in its entirety. After such action, it is then possible to bond the electrodes 22 and 24 to the bus bars 16 and 18, respectively. For example, a suitable solder composition may be used at the juncture between the electrodes and ~us bars. The solder is melted and heat and pressure are applied between the electrodes and bus bars in order to secure a good electrical junction therebetween.
It is in such a manner that an electrically conductive pattern is formed on a window in accordance with the teachings of the method of my invention. The pattern formed is one which is formed from a base metal and as such is relatively inexpensive compared to the backlites produced using metal such as silver.
~hile a particular embodiment of thls invention has been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the invention, and it is intended to cover in the appended claims all such modifications and equivalents as fall within the true spirit and scope of this invention.
METHOD FOR DEVELOPING A PATTERN ON A
CERAMIC SUBSTRATE
_ The present invention relates to the formation of a pattern on a ceramic substrate.
We are unaware of any prior art which is relevant to the method of developing an electrically conductive pattern on a ceramic substrate which is to be disclosed herein.
Howe~er, Ford Motor Company did, in a companion case, conduct a novelty study on a similar subject matter in the U.S. Patent Office. The novelty study reported several patents, all of which appear to us to be irrelevant with respect to the subject matter disclosed and claimed in this application. A brief review of these patents will be set forth below.
A number of patents cited in the novelty study are patents which deal with the coating of a metal wire with a protective layer. The protective layer may be a glass layer, and in some applications, there are a number of layers of protectïve ma~erial laid one over the other. The U.S. patents in this $xw~ mcludethe following: 3,106,490;
3,109,053; 3,294,731; 3,325,590; 3,35~,009 and 3,451,847.
None of these patents are directed to a method of developing an electrically conductive pattern on a ceramic substrate, as is disclosed and specifically claimed in this application.
The other two patents cited in the novelty study were U.S. patents 3,721,594 and 3,928,748. ~oth of these patents deal with window structures which have electrically conductive patterns thereon. In the 3,721,594 U.S. Patent, a method is disclosed for electroless plating of a grid pattern on a window. ~owever, prior to the electroless plating, the glass window has a finely divided ceramic frit placed thereon and the frit and window are passed through a glass tempering operation. U.S. 3,928,748 patent shows a heater grid structure for a window which is also made in i 157'~
a manner in which it can also serve as a radio ~ltenna.
Neither of these patents disclose or suggest the method which we are going to disclose in this speci~ication.
This invention is directed to a method for developing a pattern on a ceramic substrate and, mare particularly, to a method for developing an electrically conductive pattern on a ceramlc substrate, such as a glass window, which is subsequently used in a motor vehicle as a heated ~acklite.
In accordance wlth the prese~t invention, an electrically conductive pattern is developed on a ceramic substrate in the following manner. A thin Iayer of a heat fusable material which contains a current conducting base metal in granular form is deposited on the ceramic substrate in a desired pattern. An encasing layer of an oxygen barrier material containing an oxygen getting material is deposited over the pattern formed of heat fusable material on the ceramic substrate. The oxygen barrier material forming the encasing layer is a material which is non-heat fusabre and nonreactive with the heat fusable material forming the pattern. The ceramic substrate, the heat fusable material and the oxygen barrier material supported on the ceramlc substrate are heated in an oxygen containing ambient. The heating is to a temperature sufficient to permit the heat fusable material to fuse to the ceramic substrate. 2uring this fusing, the oxygen barrier material protects the granular, current conducting base metal of the fusable material in two manners. In a first manner, the oxygen barrier material physically blocks out the oxygen. In a second manner, the oxygen barrier material provides the getting material which chemically reacts with any oxygen which does manage to penetrate into the oxygen oarrier material, thereby keeping such oxygen away from the otherwise oxidizable base metal 35 contained in the heat fusable material. The ceramic substrate, along with the now fused 'neat fusable material, and any remaining oxygen ~arrier material supported on the~
ceramic substrate is cooled to room temperature. Any '~;^, 1 1S75'6~
remaining oxygen barcler material is then removed from the ceramic substrate, thereby 2roviding a ceramic substrate with an electrically conductive 2attern thereon formed of a base metal.
In accocdance with some of the detailed teachings of the method of thls invention, the base metal can be selected from the group consisting of aluminum and copper.
The ceramic substrate can be formed from ordinary soda lime silica glass and be, for example, in the shape of a backlite normally used in a motor vehlcle.
In accordance with still further detailed aspects of this invention, if the ceramic substrate is selected to be a soda lime silica glass, the cooling step is carried out at a rate suf~iciently fast to accomplish a tempering 15 of the glass.
The novel features that are considered ~character-istic of the invention are set forth with particularlity in the appended claims. The lnvention itself, however, both as to ~ts organization and its method of operation, together wit~ advantages thereof, will best be understood from the following description of specific embodiments when read in connec~tion with the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures, and in which:
Figure 1 is a plan view of a heated backlite usa'ble in automotive vehicles made in accordance with the method of this invention;
Figure 2 is an enlarged view of a heated backlite during an initial stage of the method of this invention:
Figure 3 is a cross section view taken along line III-III of Figure 2;
Figure 4 is a view similar to Figure 2, but showing the heated backlite in a latter stage of the method of this invention:
Figure 5 is a cross section view taken along line V-V of Figure 4; and Figure 6 is a cross-section view similar to Figure 5 but showing the heated backlite in the last stage of the method of this invention.
1 1~79~
The method about to be described is used to form electrically conductive patterns on window glass. A
ærincipal use for such a window glass may be as a heatable window structure for an automobile. In particular, the greatest utility for such window glasses are as heated backlites in automotive vehicles. When the backlite is fogged or iced over, electrical energy is flowed~through the electrically conductive pattern, causing the pattern and glass window associated therewith to be heated. This heating action removes the fog or ice that is on the window. In normal cases, the number of lines, thickness of individual lines and resistance of the pattern to the flow of electrical energy therethrough determine the amount of heat that is generated per unit of time by such a heated backlite.
In Figure 1, there is illustrated a backlite generally designated by the numeral 10. This backlite is in the form of a glass sheet 12 having a conductive electric pattern formed thereon generally designated by the :r .1 1 157~G~
numeral 14. Tne conductive pattern has oppositely placed bus bars 1~ and 13 interconnected by a plurality o~ grid lines 20-20. ~lectric terminals 22 and 24 are provided respectively on bus bars 16 and 18 to provide a means for connecting the conductive grid pattern 14 to an electrical supply system. When the electrical supply system is connected to the conductive pattern and is in operating condition, the grid lines and bus bars associated therewith carry electrical power, which in turn generates heat to melt any ice or to dispell any fog that may be on the glass sheet 12.
The method of this invention is a method for applying the conductive pattern 14 to the glass sheet 12.
The method of this invention will best be understood by reference to Figures 2 through 6. A first step in the method of this invention is illustrated in Figure 2. In this Figure, there is shown disposed on the window 12 in a desired pattern a thin layer of a heat fusable material which contains a current conducting base metal in granular form in order to define the conductive pattern 14, shown only in Figure 1. This heat fusable material is a material such as a mixture of granular copper or granular aluminum with a low melting glass frit, a preferred heat fusable materia] containing about 90% by weight of the base metal, and 10~ by weight of the glass frit. This type of heat fusable material may be applied in 2 uniform manner in the required thickness, the thickness being determined by the conductivity of the metal involved as well as other electrical factors known to a skilled artisan to generate so much heat per square unit of the backlite.
In a preferred embodiment of the method of this invention; the heat fusable material which contains a current conducting base metal in ~ranular form is applied to the glass sheet 12 in order to form the conductive 3~ pattern 14 thereon in a silk screen printing operation, which operation is well known in the art. The silk 1 1S7~
screen process provides a mask that outlines the configuration to be printed on the glass sheet. After the heat fusable material has been deposited, it may be cured at low temperatures in order to effect a temporary bonding of that heat f~sable material to the glass sheet. For example, the sheet, with the prlnting thereon, can be heated and forced air dried at 400F.
As is best illustrated in Figure ~, after the pattern of the heat fusable material which contains a current conducting base metal in granular form has been deposited on the glass sheet 12 in the conductive pattern 14, there is deposited thereover in an encasing manner an encasing layer 26 of an oxygen barrier material containing an oxygen getting material. The oxygen barrier material is also one which is non-heat fusable and nonreactive with the heat fusable material enclosed. For example, the oxygen barrier material may be a clay powder mixed with granular charcoal. The granular charcoal acts as the oxygen getting material of the oxygen barrier material.
By an oxygen barrier material it is meant a material which when placed over another material will act in a manner to bar entrance of oxygen to the enclosed material because of the manner in which the barrier material is packed over the encased material. By an oxygen getting material it is meant a material which is reactive with oxygen so that if the oxygen barrier material is penetrated by some oxygen from an oxygen ambient, the getter material will react with the oxygen and thereby protect the material lying therebelow which is enclosed.
If that material had not been protected, the base metal forming the conductlve pattern would be free to oxidize and have its electrical characteristics destroyed.
1 157~6~
In accordance with the teachings of this preferred embodiment, a dual purpose heating operation is now carried out on the glass sheet 12, the conductive pattern 14, and the oxygen barrier material 26 deposited over the conauctive pattern. The heating is to a temperature in a range of about 1100F to 1200F. Glass, when rapidly cooled from this temperature range, will be tempered. As an additional matter, when the glass sheet is 'neated to this temperature, the t'nin heat fusable material forming the conductive pattern fuses together to form an electric pattern adherent to the glass which is capable of conducting electricity therethrough for the purpose of defogging and deicing the sheet. During the heating of the glass to this elevated temperature, and while at the elevated temperature, the glass is maintained in an oxygen amb ent such as air. The reason that it is maintained ln such an ambient is that there would be tremendous costs involved if one attempted to heat such a glass sheet in an environment such as all nitrogen gas and also use all nitrogen gas in a tempering operation.
While the glass article is heated to the elevated temperature and maintained in an oxygen ambient, the oxygen barrier material 26 provides a protective coating over the conductive pattern 14 which prevents the oxidation thereof.
~The oxidation is prohibited in two manners. In a first manner, the oxygen barrier material acts as a physical barrier to exclude oxygen from the conductive pattern. In a second manner, the oxygen barrier material provides oxygen getting capabilities which, as previously explained, means that the oxygen barrier material provides a material which will reacts with any oxygen that does in fact permeate thro~gh the barrier material rather than permitting the base metal forming the conductive pattern to react with such oxygen. The oxygen barrier material, however, is one which is non-heat fusable and nonreactive with the conductive pattern it is protecting.
I lS ~g( As is well known in the art, in order to temper a glass sheet it is rapidly cooled from an elevated temperature to room temperature by the impingement of cooling air thereon. If the intended glass sheet is a product which is to be used in a motor vehicle, it will be necessary to temper the glass sheet in order to comply with the requirements of automotive glazing. Thus, if the glass sheet is to be used as a backlite in a motor vehicle, the glass sheet will be quenched rapidly from its elevated temperature to room temperature to temper the same.
During the cooling of the glass, some or all of the oxygen barrier material 26 may be blown off or blown away to expose therebelow the conductive pattern 14.
~fter the glass sheet has reached room temperature, any oxygen barrier material remaining over the conductive pattern may be washed or wiped away in order to expose the conductive pattern in its entirety. After such action, it is then possible to bond the electrodes 22 and 24 to the bus bars 16 and 18, respectively. For example, a suitable solder composition may be used at the juncture between the electrodes and ~us bars. The solder is melted and heat and pressure are applied between the electrodes and bus bars in order to secure a good electrical junction therebetween.
It is in such a manner that an electrically conductive pattern is formed on a window in accordance with the teachings of the method of my invention. The pattern formed is one which is formed from a base metal and as such is relatively inexpensive compared to the backlites produced using metal such as silver.
~hile a particular embodiment of thls invention has been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the invention, and it is intended to cover in the appended claims all such modifications and equivalents as fall within the true spirit and scope of this invention.
Claims (6)
1. A method for developing a pattern on a ceramic substrate, the pattern being formed of a material which is electrically conductive, which method comprises the steps of:
depositing on the ceramic substrate in a desired pattern a thin layer of a heat fusable material which contains a current conducting base metal in granular form;
depositing as an encasing layer over said pattern formed of heat fusable material an oxygen barrier material containing an oxygen getting material, said oxygen barrier material being non-heat fusable and nonreactive with said heat fusable material;
heating in an oxygen containing ambient the ceramic substrate along with said heat fusable material and said oxygen barrier material supported on the ceramic substrate, the heating being to a temperature sufficient to permit said heat fusable material to fuse to the ceramic substrate, said oxygen barrier material protecting said granular, current conducting base metal of said fusable material from oxidation by physically blocking out oxygen and by chemically providing an oxygen getting material which will react with any oxygen which does manage to penetrate into said oxygen barrier material;
cooling the ceramic substrate along with the now fused heat fusable material and any remaining oxygen barrier-material supported on the ceramic substrate to room temperature; and removing any of said remaining oxygen barrier material from the ceramic substrate.
depositing on the ceramic substrate in a desired pattern a thin layer of a heat fusable material which contains a current conducting base metal in granular form;
depositing as an encasing layer over said pattern formed of heat fusable material an oxygen barrier material containing an oxygen getting material, said oxygen barrier material being non-heat fusable and nonreactive with said heat fusable material;
heating in an oxygen containing ambient the ceramic substrate along with said heat fusable material and said oxygen barrier material supported on the ceramic substrate, the heating being to a temperature sufficient to permit said heat fusable material to fuse to the ceramic substrate, said oxygen barrier material protecting said granular, current conducting base metal of said fusable material from oxidation by physically blocking out oxygen and by chemically providing an oxygen getting material which will react with any oxygen which does manage to penetrate into said oxygen barrier material;
cooling the ceramic substrate along with the now fused heat fusable material and any remaining oxygen barrier-material supported on the ceramic substrate to room temperature; and removing any of said remaining oxygen barrier material from the ceramic substrate.
2. The method of Claim 1 wherein: said thin layer of a heat fusable material contains a current conducting base metal selected from the group consisting of aluminum and copper.
3. The method of Claims 1 or 2 wherein: the cooling of the ceramic substrate, along with the fused heat fusable material and any remaining oxygen barrier material supported on the ceramic substrate to room temperature is accomplished in a rapid manner in order to temper the ceramic substrate.
4. A method for developing an electrically conductive pattern on a glass sheet, which method comprises the steps of:
depositing on the glass sheet in a desired pattern a thin layer of a heat fusable material which contains a current conducting base metal in granular form;
depositing as an encasing layer over said pattern formed of heat fusable material an oxygen barrier material containing an oxygen getting material, said oxygen barrier material being non-heat fusable and nonreactive with said heat fusable material;
heating in an oxygen containing ambient the glass sheet along with said heat fusable material and said oxygen barrier material supported on the glass sheet, the heating being to a temperature sufficient to permit said heat fusable material to fuse to the glass sheet, said oxygen barrier material protecting said granular, current conducting base metal of said fusable material from oxidation by physically blocking out oxygen and by chemically providing an oxygen getting material which will react with any oxygen which does manage to penetrate into said oxygen barrier material;
cooling the glass sheet along with the now fused heat fusable material and any remaining oxygen barrier material supported on the glass sheet to room temperature;
removing any of said remaining oxygen barrier material from the glass sheet; and forming a junction capable of carrying current with at least a portion of the now fused heat fusable material.
-11 _
depositing on the glass sheet in a desired pattern a thin layer of a heat fusable material which contains a current conducting base metal in granular form;
depositing as an encasing layer over said pattern formed of heat fusable material an oxygen barrier material containing an oxygen getting material, said oxygen barrier material being non-heat fusable and nonreactive with said heat fusable material;
heating in an oxygen containing ambient the glass sheet along with said heat fusable material and said oxygen barrier material supported on the glass sheet, the heating being to a temperature sufficient to permit said heat fusable material to fuse to the glass sheet, said oxygen barrier material protecting said granular, current conducting base metal of said fusable material from oxidation by physically blocking out oxygen and by chemically providing an oxygen getting material which will react with any oxygen which does manage to penetrate into said oxygen barrier material;
cooling the glass sheet along with the now fused heat fusable material and any remaining oxygen barrier material supported on the glass sheet to room temperature;
removing any of said remaining oxygen barrier material from the glass sheet; and forming a junction capable of carrying current with at least a portion of the now fused heat fusable material.
-11 _
5. The method of Claim 4 wherein: said thin layer of heat usable material contains a granular form current conducting base metal selected from the group consisting of aluminum and copper.
6. The method of Claims 4 or 5 wherein: the cooling of the glass sheet, the fused heat fusable material, and any remaining oxygen barrier material supported on the glass sheet, to room temperature is accomplished in a rapid manner in order to temper the glass sheet.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/178,416 US4294867A (en) | 1980-08-15 | 1980-08-15 | Method for developing a pattern on a ceramic substrate |
| US178,416 | 1980-08-15 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1157965A true CA1157965A (en) | 1983-11-29 |
Family
ID=22652479
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000379582A Expired CA1157965A (en) | 1980-08-15 | 1981-06-11 | Method for developing a pattern on a ceramic substrate |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US4294867A (en) |
| EP (1) | EP0046359B1 (en) |
| JP (1) | JPS5751182A (en) |
| CA (1) | CA1157965A (en) |
| DE (1) | DE3167827D1 (en) |
Families Citing this family (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4407847A (en) * | 1981-12-28 | 1983-10-04 | Ford Motor Company | Process for the manufacture of glass sheets |
| CA2020172C (en) * | 1989-07-03 | 1993-11-30 | John A. Winter | Heatable windshield notch sealant |
| US5066111A (en) * | 1989-09-13 | 1991-11-19 | Ppg Industries, Inc. | Electrochromic window with integrated bus bars |
| DE19756988C1 (en) * | 1997-12-20 | 1999-09-02 | Daimler Benz Ag | Electrically heated glow plug or glow stick for internal combustion engines |
| US6892441B2 (en) | 2001-04-23 | 2005-05-17 | Appleton Papers Inc. | Method for forming electrically conductive pathways |
| US6779246B2 (en) | 2001-04-23 | 2004-08-24 | Appleton Papers Inc. | Method and system for forming RF reflective pathways |
| TW538662B (en) * | 2002-05-10 | 2003-06-21 | Shang Chuen Weighting Machine | Method of producing reinforced glass circuit boards |
| US20080003416A1 (en) * | 2005-01-19 | 2008-01-03 | Watson Rodney B | Decorative Articles for Automotive Glazing and Methods of Making the Same |
| US20060159893A1 (en) * | 2005-01-19 | 2006-07-20 | Visteon Global Technologies, Inc. | Decorative articles for automotive glazing and methods of making same |
| US20100112324A1 (en) * | 2009-08-06 | 2010-05-06 | Boaz Premakaran T | Coatings on Glass |
| JP6832658B2 (en) * | 2016-09-23 | 2021-02-24 | スタンレー電気株式会社 | Light transmission board, display device, signal device, and lighting device |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2225729A (en) * | 1938-04-29 | 1940-12-24 | Libbey Owens Ford Glass Co | Method of coloring vitreous articles |
| US3048495A (en) * | 1959-07-02 | 1962-08-07 | Standard Oil Co | Temporary oxidation-preventive coating for metal |
| US3106490A (en) * | 1960-10-21 | 1963-10-08 | Physical Sciences Corp | Ceramic material and method of coating |
| US3109053A (en) * | 1961-01-05 | 1963-10-29 | Raytheon Co | Insulated conductor |
| US3294731A (en) * | 1962-03-08 | 1966-12-27 | Anaconda Wire & Cable Co | Pyrolizable enamel from mn and co chelates, glass, and siloxane resin |
| US3352009A (en) * | 1962-12-05 | 1967-11-14 | Secon Metals Corp | Process of producing high temperature resistant insulated wire, such wire and coils made therefrom |
| US3325590A (en) * | 1964-03-23 | 1967-06-13 | Westinghouse Electric Corp | Insulated conductors and method of making the same |
| DE1521618B2 (en) * | 1965-02-17 | 1971-03-11 | The English Electric Co Ltd , London | METHOD OF APPLYING AN INSULATING GLASS COATING TO METAL WIRE OR STRIP |
| GB1202522A (en) * | 1966-08-08 | 1970-08-19 | Triplex Safety Glass Co | Electrical components applied to vitreous bodies |
| GB1194090A (en) * | 1967-11-09 | 1970-06-10 | Asahi Glass Co Ltd | Improvements in or relating to Electrically Heatable Glass Products |
| JPS508452B1 (en) * | 1967-11-09 | 1975-04-04 | ||
| US3721594A (en) * | 1969-07-01 | 1973-03-20 | Ppg Industries Inc | Applying electroconductive heating circuits to glass |
| IT986606B (en) * | 1972-07-21 | 1975-01-30 | Glaverbel | PROCEDURE FOR MANUFACTURING A TRANSPARENT HEATING PANEL AND THE OBTAINED PANEL |
| FR2250329A5 (en) * | 1973-10-31 | 1975-05-30 | Saint Gobain | |
| US4189509A (en) * | 1976-09-09 | 1980-02-19 | Texas Instruments Incorporated | Resistor device and method of making |
-
1980
- 1980-08-15 US US06/178,416 patent/US4294867A/en not_active Expired - Lifetime
-
1981
- 1981-06-11 CA CA000379582A patent/CA1157965A/en not_active Expired
- 1981-08-10 DE DE8181303638T patent/DE3167827D1/en not_active Expired
- 1981-08-10 EP EP81303638A patent/EP0046359B1/en not_active Expired
- 1981-08-14 JP JP56126851A patent/JPS5751182A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5751182A (en) | 1982-03-25 |
| DE3167827D1 (en) | 1985-01-31 |
| US4294867A (en) | 1981-10-13 |
| EP0046359A1 (en) | 1982-02-24 |
| EP0046359B1 (en) | 1984-12-19 |
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